Aerosol delivery system with an activation surface

ABSTRACT

There is disclosed a fluid-transfer article which is suitable for use as part of an aerosol-generating system. The fluid-transfer-article comprises a first region for holding an aerosol precursor and for transferring said aerosol precursor to an activation surface of a second region of said article. The activation surface is disposed at an end of said article configured for thermal interaction with a heater of an aerosol-generation apparatus. At least the second region of the fluid-transfer article is formed from a polymeric wicking material.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a U.S. 371 Application from PCT/EP2018/060500 Apr.24, 2018, which claims priority from GB1706593.9 filed 25 Apr. 2017;GB1802836.5 filed 22 Feb. 2018; and from GB1802837.3 filed 22 Feb. 2018,the contents and elements of which are herein incorporated by referencefor all purposes.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENTS

Not applicable.

THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not applicable.

INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC OR ASA TEXT FILE VIA THE OFFICE ELECTRONIC FILING SYSTEM (EFS-WEB)

Not applicable.

STATEMENT REGARDING PRIOR DISCLOSURES BY THE INVENTOR OR A JOINTINVENTOR

Not applicable.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to an aerosol delivery system, a carrierfor an aerosol precursor and a fluid-transfer article for an aerosoldelivery system. In particular, the present invention relates to anaerosol delivery system comprising a heater configured to heat anaerosol precursor to generate an aerosolised composition for inhalationby a user.

DESCRIPTION OF RELATED ART INCLUDING INFORMATION DISCLOSED UNDER 37 CFR1.97 AND 1.98

Pharmaceutical medicament, physiologically active substances andflavourings for example may be delivered to the human body by inhalationthrough the mouth and/or nose. Such material or substances may bedelivered directly to the mucosa or mucous membrane lining the nasal andoral passages and/or the pulmonary system. For example, nicotine isconsumed for therapeutic or recreational purposes and may be deliveredto the body in a number of ways. Nicotine replacement therapies areaimed at people who wish to stop smoking and overcome their dependenceon nicotine. Nicotine is delivered to the body in the form of aerosoldelivery devices and systems, also known as smoking-substitute devicesor nicotine delivery devices. Such devices may be non-powered orpowered.

Devices or systems that are non-powered may comprise nicotinereplacement therapy devices such as “inhalators”, e.g. Nicorette®Inhalator. These generally have the appearance of a plastic cigaretteand are used by people who crave the behaviour associated withconsumption of combustible tobacco—the so-called hand-to-mouth aspect—ofsmoking tobacco. Inhalators generally allow nicotine-containing aerosolto be inhaled through an elongate tube in which a container containing anicotine carrier, for example, a substrate, is located. An air streamcaused by suction through the tube by the user carries nicotine vapoursinto the lungs of the user to satisfy a nicotine craving. The containermay comprise a replaceable cartridge, which includes a cartridge housingand a passageway in the housing in which a nicotine reservoir islocated. The reservoir holds a measured amount of nicotine in the formof the nicotine carrier. The measured amount of nicotine is an amountsuitable for delivering a specific number of “doses”. The form of thenicotine carrier is such as to allow nicotine vapour to be released intoa fluid stream passing around or through the reservoir. This process isknown as aerosolization and or atomization. Aerosolization is theprocess or act of converting a physical substance into the form ofparticles small and light enough to be carried on the air i.e. into anaerosol. Atomization is the process or act of separating or reducing aphysical substance into fine particles and may include the generation ofaerosols. The passageway generally has an opening at each end forcommunication with the exterior of the housing and for allowing thefluid stream through the passageway. A nicotine-impermeable barrierseals the reservoir from atmosphere. The barrier includes passagewaybarrier portions for sealing the passageway on both sides of thereservoir. These barrier portions are frangible so as to be penetrablefor opening the passageway to atmosphere.

A device or a system that is powered can fall into two sub-categories.In both subcategories, such devices or systems may comprise electronicdevices or systems that permit a user to simulate the act of smoking byproducing an aerosol mist or vapour that is drawn into the lungs throughthe mouth and then exhaled. The electronic devices or systems typicallycause the vaporization of a liquid containing nicotine and entrainmentof the vapour into an airstream. Vaporization of an element or compoundis a phase transition from the liquid phase to vapour i.e. evaporationor boiling. In use, the user experiences a similar satisfaction andphysical sensation to those experienced from a traditional smoking ortobacco product, and exhales an aerosol mist or vapour of similarappearance to the smoke exhaled when using such traditional smoking ortobacco products.

A person of ordinary skill in the art will appreciate that devices orsystems of the second, powered category as used herein include, but arenot limited to, electronic nicotine delivery systems, electroniccigarettes, e-cigarettes, e-cigs, vaping cigarettes, pipes, cigars,cigarillos, vaporizers and devices of a similar nature that function toproduce an aerosol mist or vapour that is inhaled by a user. Suchnicotine delivery devices or systems of the second category incorporatea liquid reservoir element generally including a vaporizer or mistingelement such as a heating element or other suitable element, and areknown, inter alia, as atomizers, cartomizers, or clearomizers. Someelectronic cigarettes are disposable; others are reusable, withreplaceable and refillable parts.

Aerosol delivery devices or systems in a first sub-category of thesecond, powered category generally use heat and/or ultrasonic agitationto vaporize a solution comprising nicotine and/or other flavouring,propylene glycol and/or glycerine-based base into an aerosol mist ofvapour for inhalation.

Aerosol delivery devices or systems in a second sub-category of thesecond, powered category may typically comprise devices or systems inwhich tobacco is heated rather than combusted. During use, volatilecompounds may be released from the tobacco by heat transfer from theheat source and entrained in air drawn through the aerosol deliverydevice or system. Direct contact between a heat source of the aerosoldelivery device or system and the tobacco heats the tobacco to form anaerosol. As the aerosol containing the released compounds passes throughthe device, it cools and condenses to form an aerosol for inhalation bythe user. In such devices or systems, heating, as opposed to burning,the tobacco may reduce the odour that can arise through combustion andpyrolytic degradation of tobacco.

Aerosol delivery devices or systems falling into the first sub-categoryof powered devices or systems may typically comprise a powered unit,comprising a heater element, which is arranged to heat a portion of acarrier that holds an aerosol precursor. The carrier comprises asubstrate formed of a “wicking” material, which can absorb aerosolprecursor liquid from a reservoir and hold the aerosol precursor liquid.Upon activation of the heater element, aerosol precursor liquid in theportion of the carrier in the vicinity of the heater element isvaporised and released from the carrier into an airstream flowing aroundthe heater and carrier. Released aerosol precursor is entrained into theairstream to be borne by the airstream to an outlet of the device orsystem, from where it can be inhaled by a user.

The heater element is typically a resistive coil heater, which iswrapped around a portion of the carrier and is usually located in theliquid reservoir of the device or system. Consequently, the surface ofthe heater may always be in contact with the aerosol precursor liquid,and long-term exposure may result in the degradation of either or bothof the liquid and heater. Furthermore, residues may build up upon thesurface of the heater element, which may result in undesirable toxicantsbeing inhaled by the user. Furthermore, as the level of liquid in thereservoir diminishes through use, regions of the heater element maybecome exposed and overheat.

The present invention has been devised in light of the aboveconsiderations.

BRIEF SUMMARY OF THE INVENTION

According to an aspect of the present invention, there is provided afluid-transfer article comprising: a first region for holding an aerosolprecursor and for transferring said aerosol precursor to an activationsurface of a second region of said article, said activation surfacebeing disposed at an end of said article configured for thermalinteraction with a heater of an aerosol-generation apparatus; wherein atleast said second region is formed from a polymeric wicking material.

Optionally, said first and second regions are both formed from saidpolymeric wicking material.

Conveniently, said polymeric wicking material comprises Polyetherimide(PEI).

Advantageously, said polymeric wicking material comprises Polyetherether ketone (PEEK).

Optionally, said polymeric wicking material comprisesPolytetrafluoroethylene (PTFE).

Conveniently, said polymeric wicking material comprises Polyimide (PI).

Advantageously, said polymeric wicking material comprisesPolyethersulphone (PES).

Optionally, said polymeric wicking material comprises Ultra-HighMolecular Weight Polyethylene (UHMWPE).

Conveniently, said polymeric wicking material comprises Polypropylene(PP).

Advantageously, said polymeric wicking material comprises PolyethyleneTerephthalate (PET).

Optionally, said polymeric wicking material is porous.

Conveniently, said material is configured such that pore diameter insaid first region is greater than pore diameter in said second region.

Advantageously, said polymeric wicking material is heat resistant.

Optionally, said polymeric wicking material is a hydrophilic materialthat is configured to transfer fluid from said first region to saidsecond region.

Conveniently, said polymeric wicking material is of greaterhydrophilicity in said second region than said first region.

Advantageously, said polymeric wicking material is a sintered material.

Optionally, said polymeric wicking material comprises a graduatedwicking action.

Conveniently, said second region comprises at least one discontinuity insaid activation surface to form a corresponding at least one channelbetween said activation surface and an opposing surface through whichheat is conveyable to said activation surface from a heater, said atleast one channel configured for providing a fluid pathway across saidactivation surface, said fluid pathway across said activation surfaceforming a portion of said fluid pathway between said first end and saidsecond end.

Optionally, the fluid-transfer article is provided within a carrier foran aerosol precursor, the carrier comprising: a housing for engagementwith an aerosol-generating apparatus, said housing being configured toprovide a fluid pathway between a first end that is disposed in fluidengagement with an inlet of said aerosol-generating apparatus and asecond end that is disposed in fluid engagement with an outlet of saidaerosol-generating apparatus; the fluid-transfer article being providedwithin said housing.

Conveniently, the carrier is provided as part of an aerosol-deliverysystem, the system further comprising an aerosol-generation apparatushaving a heater.

According to another aspect of the present invention, there is provideda fluid-transfer article comprising: a first region for holding anaerosol precursor and for transferring said aerosol precursor to anactivation surface of a second region of said article, said activationsurface being disposed at an end of said article configured for thermalinteraction with a heater of an aerosol-generation apparatus; and aliquid-impermeable peripheral wall surrounding at least a portion ofsaid first region; wherein said first region comprises a storagesubstrate in which said aerosol precursor is held; and wherein saidperipheral wall and said storage substrate are formed integrally fromthe same material as a one-piece unit.

Optionally, said storage substrate is porous, and said peripheral wallis non-porous.

Conveniently, wherein said peripheral wall is defined by a skin formedfrom the material of said storage substrate.

Advantageously, said peripheral wall substantially completelycircumscribes said storage substrate.

Optionally, at least said storage substrate is formed from porousmaterial, an outermost surface of which has been treated to render itliquid impermeable and thereby define said peripheral wall.

Conveniently, said outermost surface is heat-treated.

Advantageously, said outermost surface is chemically treated.

Optionally, the article is provided in the form of a unitary monolithicelement formed of said material, wherein said peripheral wall defines anouter surface of the fluid-transfer article across substantially theentire extent of said monolithic element, except said activationsurface.

Conveniently, said material is a polymeric wicking material.

Advantageously, said first and second regions are both formed from saidpolymeric wicking material.

Optionally, said material comprises Polyetherimide (PEI).

Conveniently, said material comprises Polyether ether ketone (PEEK).

Optionally, said material comprises Polytetrafluoroethylene (PTFE).

Conveniently, said material comprises Polyimide (PI).

Advantageously, said material comprises Polyethersulphone (PES).

Optionally, said material comprises Ultra-High Molecular WeightPolyethylene (UHMWPE).

Conveniently, said material comprises Polypropylene (PP).

Advantageously, wherein said material comprises PolyethyleneTerephthalate (PET).

Optionally, said second region comprises at least one discontinuity insaid activation surface to form a corresponding at least one channelbetween said activation surface and an opposing surface through whichheat is conveyable to said activation surface from a heater, said atleast one channel configured for providing a fluid pathway across saidactivation surface, said fluid pathway across said activation surfaceforming a portion of said fluid pathway between said first end and saidsecond end.

Conveniently, the fluid-transfer article forms part of a carrier for anaerosol precursor.

Optionally, the carrier is provided in the form of a consumable for anaerosol-delivery system, wherein said storage substrate contains aliquid aerosol precursor.

Conveniently, the carrier is provided as part of an aerosol-deliverysystem, the system further comprising an aerosol-generation apparatushaving a heater.

According to another aspect of the present invention, there is provideda fluid-transfer article comprising: a first region for holding anaerosol precursor and for transferring said aerosol precursor to anactivation surface of a second region of said article, said activationsurface being disposed at an end of said article configured for thermalinteraction with a heating surface of an aerosol-generation apparatus;said activation surface including at least one angled surface portionand being configured such that, when the fluid-transfer article isarranged with respect to a said heating surface for thermal interactiontherebetween, the or each said angled surface portion forms an acuteintersection angle with said heating surface.

Optionally, said second region comprises at least one discontinuity insaid activation surface to form a corresponding at least one channelbetween said activation surface and said heating surface, the or eachsaid channel being configured for providing a fluid pathway across saidactivation surface, and being at least partly defined by a said angledsurface portion in the form of a wall of the channel.

Conveniently, the or each said channel is at least partly defined by apair of said angled surface portions, said pair of angled surfaceportions opposing one another across said channel to form opposite wallsof the channel.

Advantageously, the or each said channel comprises a ceiling portionbetween said opposite walls of the channel.

Optionally, the ceiling portion of the or each said channel issubstantially planar.

Conveniently, the ceiling portion of the or each said channel issubstantially parallel to said heating surface.

Advantageously, said ceiling portion of the or each said channel isarcuate.

Optionally, the fluid-transfer article is provided in combination with aheater, wherein the heater comprises a substrate defining said heatingsurface, and at least one heating element formed on said heatingsurface.

Conveniently, the or each said heating element extends substantiallyadjacent a line at which a respective said angled surface portionintersects said heating surface.

Advantageously, the fluid-transfer article comprises a plurality of saidangled surface portions, each said angled surface portion beingconfigured to make a substantially equal intersection angle with saidheating surface.

Optionally, the or each said intersection angle is greater than 10degrees. Optionally, the or each said intersection angle is greater than20 degrees. Optionally, the or each said intersection angle is greaterthan 30 degrees. Optionally, the or each said intersection angle isgreater than 40 degrees. Optionally, the or each said intersection angleis greater than 50 degrees. Optionally, the or each said intersectionangle is greater than 60 degrees. Optionally, the or each saidintersection angle is greater than 70 degrees. Optionally, the or eachsaid intersection angle is greater than 80 degrees. Optionally, the oreach said intersection angle is less than 80 degrees. Optionally, the oreach said intersection angle is less than 70 degrees. Optionally, the oreach said intersection angle is less than 60 degrees. Optionally, the oreach said intersection angle is less than 50 degrees. Optionally, the oreach said intersection angle is less than 40 degrees. Optionally, the oreach said intersection angle is less than 30 degrees. Optionally, the oreach said intersection angle is less than 20 degrees. Optionally, the oreach said intersection angle is less than 10 degrees.

Conveniently, at least said second region is formed from a polymericwicking material.

Advantageously, said first and second regions are both formed from saidpolymeric wicking material.

Optionally, said polymeric wicking material is porous.

Conveniently, said polymeric wicking material is configured such thatpore diameter in said first region is greater than pore diameter in saidsecond region.

Advantageously, said polymeric wicking material is heat resistant.

Optionally, said polymeric wicking material is a hydrophilic materialthat is configured to transfer fluid from said first region to saidsecond region.

Conveniently, said polymeric wicking material is of greaterhydrophilicity in said second region than said first region.

Optionally, the fluid-transfer article forms part of a carrier for anaerosol precursor, the carrier comprising: a housing for engagement withan aerosol-generating apparatus, said housing being configured toprovide a fluid pathway between a first end that is disposed in fluidengagement with an inlet of said aerosol-generating apparatus and asecond end that is disposed in fluid engagement with an outlet of saidaerosol-generating apparatus; wherein the fluid-transfer article isprovided within said housing.

Conveniently, the carrier is provided as part of an aerosol-deliverysystem, the system further comprising an aerosol-generation apparatushaving a heater defining a said heating surface.

According to another aspect of the present invention, there is provideda fluid-transfer article comprising: a first region for holding anaerosol precursor and for transferring said aerosol precursor to anactivation surface of a second region of said article, said activationsurface being disposed at an end of said article configured for thermalinteraction with a heating surface of an aerosol-generation apparatus;said activation surface including at least one arcuate surface portionand being configured such that, when the fluid-transfer article isarranged with respect to a said heating surface for thermal interactiontherebetween, the or each said arcuate surface portion opposes saidheating surface and is concave towards said heating surface.

Optionally, said activation is configured such that, when thefluid-transfer article is arranged with respect to a said heatingsurface for thermal interaction therebetween, the or each said arcuatesurface portion is spaced apart from said heating surface.

Conveniently, said second region comprises at least one discontinuity insaid activation surface to form a corresponding at least one channelbetween said activation surface and said heating surface, the or eachsaid channel being configured for providing a fluid pathway across saidactivation surface, and being at least partly defined by a respectivesaid arcuate surface portion, said arcuate surface portion defining atleast part of an internal surface of the channel.

Advantageously, the or each said channel is at least partly defined by apair of spaced apart side walls, said arcuate surface portion extendingbetween said wall portions to form a ceiling portion of said channel.

Optionally, said arcuate surface portion blends smoothly with each ofsaid side walls, thereby eliminating a sharp corner therebetween.

Conveniently, said side walls are substantially planar.

Advantageously, the fluid-transfer article is provided in combinationwith a said heater, wherein the heater comprises a substrate definingsaid heating surface, and at least one heating element formed on saidheating surface.

Optionally, the or each said heating element extends in substantialalignment with a respective said channel.

Conveniently, at least said second region is formed from a polymericwicking material.

Advantageously, said first and second regions are both formed from saidpolymeric wicking material.

Optionally, said polymeric wicking material is porous.

Conveniently, said polymeric wicking material is configured such thatpore diameter in said first region is greater than pore diameter in saidsecond region.

Advantageously, said polymeric wicking material is heat resistant.

Optionally, said polymeric wicking material is a hydrophilic materialthat is configured to transfer fluid from said first region to saidsecond region.

Conveniently, said polymeric wicking material is of greaterhydrophilicity in said second region than said first region.

Optionally, the fluid-transfer article forms part of a carrier for anaerosol precursor, the carrier comprising: a housing for engagement withan aerosol-generating apparatus, said housing being configured toprovide a fluid pathway between a first end that is disposed in fluidengagement with an inlet of said aerosol-generating apparatus and asecond end that is disposed in fluid engagement with an outlet of saidaerosol-generating apparatus; wherein the fluid-transfer article isprovided within said housing.

Optionally, the carrier is provided as part of an aerosol-deliverysystem, the system further comprising an aerosol-generation apparatushaving a said heater.

According to another aspect of the present invention, there is providedan aerosol-delivery system comprising: a heater having a heatingsurface; and a fluid-transfer article; said fluid-transfer articlecomprising a first region for holding an aerosol precursor and fortransferring said aerosol precursor to an activation surface of a secondregion of said article; said activation surface being disposed forthermal interaction with said heating surface; said second regioncomprising a discontinuity in said activation surface to form acorresponding channel between said activation surface and said heatingsurface; said channel being configured to provide an airflow pathwayacross said activation surface; wherein said heater comprises a heatingelement located at said heating surface, said heating element beingsubstantially aligned with said channel.

Optionally, said channel and said heating element are both elongate,said heating element being substantially parallel to a longitudinal axisof said channel.

Conveniently, said heating element is substantially aligned along acentreline of said channel.

Advantageously, said heating element is parallel to, but offset from, acentreline of said channel.

Optionally, said activation surface includes a plurality of saidchannels.

Conveniently, said heater comprises a plurality of said heatingelements.

Advantageously, the or each said channel is aligned with at least onesaid heating element.

Optionally, the or each said channel is aligned with a plurality of saidheating elements.

Conveniently, a pair of said heating elements are aligned with the oreach said channel, each of said pair of heating elements being offset toopposite sides of the centreline of the channel.

Advantageously, said heating surface comprises at least one fluidtransport region adjacent said heating element; the or each said fluidtransport region being configured to move liquid across said heatingsurface towards the or each heating element.

Optionally, the or each said fluid transport region compriseshydrophobic material

Conveniently, the or each said fluid transport region comprises aplurality of elongate regions of hydrophobic material.

Advantageously, said elongate regions of hydrophobic material aresubstantially parallel.

Optionally, the or each said heating element is substantially linear,and elongate regions of hydrophobic material are oriented substantiallyperpendicular to the or each said heating element.

Conveniently, the or each said fluid transport region comprises at leastone capillary channel.

Advantageously, the or each said fluid transport region comprises aplurality of capillary channels.

Optionally, said capillary channels are substantially parallel.

Conveniently, the or each said capillary channel is formed in saidheating surface as an open groove.

Optionally, the or each said heating element is substantially linear,and the or each said capillary channel is oriented substantiallyperpendicular to the or a said heating element.

Conveniently, the or each said heating element is a resistive heatingfilament.

According to another aspect of the present invention, there is providedan aerosol-generation apparatus, the apparatus comprising a heaterhaving a planar heating surface, and being configured to receive anaerosol precursor carrier for thermal interaction with said heatingsurface; wherein said heater comprises a heating element at said heatingsurface, and said heating surface comprises a fluid transport regionadjacent said heating element; said fluid transport region beingconfigured to move liquid across said heating surface towards theheating element.

Optionally, said fluid transport region comprises hydrophobic material

Conveniently, said fluid transport region comprises a plurality ofelongate regions of hydrophobic material.

Advantageously, said elongate regions of hydrophobic material aresubstantially parallel.

Optionally, said heating element is substantially linear, and saidelongate regions of hydrophobic material are oriented substantiallyperpendicular to said heating element.

Conveniently, said fluid transport region comprises at least onecapillary channel.

Advantageously, said fluid transport region comprises a plurality ofcapillary channels.

Optionally, said capillary channels are substantially parallel.

Conveniently, the or each said capillary channel is formed in saidheating surface as an open groove.

Advantageously, said heating element is substantially linear, and the oreach said capillary channel is oriented substantially perpendicular tosaid heating element.

Optionally, said heating element intersects the or each capillarychannel.

Conveniently, said fluid transport region comprises porous material.

Optionally, said porous material is a porous ceramic.

Advantageously, said porous material is liquid-permeable.

Optionally, said porous material is provided in the form of a layerpositioned on an underlying layer of liquid-impermeable material.

Conveniently, said layer of porous material extends beneath said heatingelement.

Advantageously, said heating element comprises a resistive heatingfilament.

Optionally, the aerosol-generation apparatus forms part of anaerosol-delivery system, the system further comprising a said carrier;the carrier comprising a fluid-transfer article; wherein saidfluid-transfer article comprises a first region for holding an aerosolprecursor and for transferring said aerosol precursor to an activationsurface of a second region of said article, said activation surfacebeing disposed at an end of said carrier configured for thermalinteraction said heating surface; wherein said second region comprisesat least one discontinuity in said activation surface to form acorresponding at least one air flow channel between said activationsurface and said heating surface, said at least one air flow channelbeing configured to provide an airflow pathway across said activationsurface.

Optionally, said heating element is substantially aligned with a saidair flow channel formed by said discontinuity in said activationsurface.

Conveniently, the or each said capillary channel extends at least froman edge of a said air flow channel to said heating element.

Advantageously, the or each said elongate region of hydrophobic materialextends at least from an edge of a said air flow channel to said heatingelement.

According to another aspect of the present invention, there is providedan aerosol-generation apparatus, the apparatus comprising a heaterhaving a heating surface, and being configured to receive an aerosolprecursor carrier for thermal interaction with said heating surface;wherein said heater comprises a porous material defining at least aregion said heating surface, and a heating element located upon saidporous material at said heating surface.

Optionally, said porous material is a porous ceramic material.

Conveniently, said porous material defines substantially the entireextent of said heating surface.

Advantageously, said porous material is liquid-permeable.

Optionally, said heater comprises a supporting substrate on which saidporous material is provided as a layer.

Conveniently, said supporting substrate is formed from substantiallyliquid-impermeable material.

Advantageously, said heater comprises a plurality of said heatingelements upon said porous material.

Optionally, the or each said heating element comprises a resistiveheating filament.

Conveniently, the aerosol-generation apparatus is provided as part of anaerosol-delivery system which further comprises a said carrier, thecarrier comprising a fluid-transfer article; wherein said fluid-transferarticle comprises a first region for holding an aerosol precursor andfor transferring said aerosol precursor to an activation surface of asecond region of said article, said activation surface being disposed atan end of said carrier configured for thermal interaction said heatingsurface; wherein the or each said heating element is located betweensaid activation surface and said porous material defining the heatingsurface.

Optionally, at least a region of said activation surface contacts saidporous material defining the heating surface.

Conveniently, said second region of said fluid-transfer articlecomprises at least one discontinuity in said activation surface to forma corresponding at least one air flow channel between said activationsurface and said heating surface, said at least one air flow channelbeing configured to provide an airflow pathway across said activationsurface.

Advantageously, the or each said heating element is aligned with arespective said air flow channel formed by said discontinuity in saidactivation surface.

According to another aspect of the present invention, there is providedan aerosol delivery system comprising: an aerosol-generation apparatuscomprising: a receptacle for receiving a carrier; a heater; a carrierfor an aerosol precursor comprising: a housing for location in saidreceptacle, said housing configured to provide a fluid pathway between afirst end that is disposed in fluid engagement with an inlet of saidaerosol-generating apparatus and a second end that is disposed in fluidengagement with an outlet of said aerosol-generating apparatus; and afluid-transfer article located within said housing, said fluid-transferarticle comprising a first region for holding an aerosol precursor andfor transferring said aerosol precursor to an activation surface of asecond region of said article, said activation surface disposed at anend of said carrier configured for thermal interaction with a heater ofsaid aerosol-generation apparatus; wherein said second region comprisesat least one discontinuity in said activation surface to form acorresponding at least one channel between said activation surface andan opposing surface through which heat is conveyable to said activationsurface from said heater, said at least one channel configured forproviding a fluid pathway across said activation surface, said fluidpathway across said activation surface forming a portion of said fluidpathway between said first end and said second end.

Optionally, said article may comprise a tubular member. Furtheroptionally, said article may comprise a bore extending therethrough,said first region extending axially along an external surface of saidarticle and said second surface, located between said first region andsaid bore, extending axially along an internal surface of said article,said at least one discontinuity extending axially along said internalsurface of said article formed by said bore. Yet further optionally,said article may comprise a bore extending therethrough, said firstregion extending axially along an internal surface of said article andsaid second surface extending axially along an external surface of saidarticle, said at least one discontinuity extending axially at leastpartially along said external surface of said article.

Optionally, an end surface of said tubular member may comprise saidactivation surface and further wherein said at least one discontinuitymay extend radially across said activation surface.

Optionally, an end surface of said tubular member may comprise saidactivation surface and further wherein said at least one discontinuitymay extend linearly across said activation surface.

Optionally, an end surface of said tubular member may comprise saidactivation surface and further wherein said at least one discontinuitymay be convolute, meandering and/or serpentine across said activationsurface.

Optionally, said activation surface may be formed at an interfacebetween regions adjacent said at least one discontinuity and saidopposing surface through which heat is conveyed to said activationsurface from said heater.

Optionally, said heater may comprise a planar heating surface.

Optionally, said heater may be a rod extending axially through saidcentre of said fluid-transfer article.

Optionally, said heater may comprise a collar arranged around saidarticle.

Optionally, said collar may extend over a length of said article.

Optionally, said collar may extend over said second region of saidarticle.

Optionally, said heater may comprise said opposing surface through whichheat is conveyed to said activation surface, said heater in contact withsaid activation surface of said article.

Optionally, a thermally conductive barrier layer may be provided as saidopposing surface through which heat is conveyable to said activationsurface, said thermally conductive barrier layer in thermal contact withsaid heater and located between said heater and said activation surfaceof said article.

Optionally, said activation surface and said opposing surface throughwhich heat is conveyable to said activation surface may becomplementary. This may maintain a temperature gradient through the atleast one channel for consistency of activation.

Optionally, said activation surface and said heater surface may becomplementary.

Optionally, said article may be formed of a thermally conductivematerial.

Optionally, said article may be formed of a plastic material, such as,for example, Polyetherimide or Polytetrafluoroethylene (PTFE). Othersuitable materials may comprise, for example, BioVyon™ (by PorvairFiltration Group Ltd) and materials available from Porex®. Furtheroptionally, a substrate fonning the fluid-transfer article may comprisepolypropylene or polyethylene terephthalate.

Optionally, said article may be formed from a hydrophilic material thatis configured to transfer fluid from said first region to said secondregion.

Optionally, said article may be formed from a sintered material.

Optionally, said article may comprise a plurality of regions havingdifferent structures.

Optionally, said article may be formed of a porous material in whichpore diameter in said first region is greater than pore diameter in saidsecond region.

Optionally, said article may be formed of a material that is of greaterhydrophilicity in said second region than said first region.

Optionally, said article may be formed of a wicking material comprisinga graduated wicking action.

Optionally, said heater may comprise a material of at least one of: aceramic; and a metal. Optionally, a first end and a second end of saidhousing may be sealed with a removable end cap. The end caps areremovable prior to the carrier being located in said apparatus.

Optionally, a first end and a second end of said housing may be sealedwith a frangible barrier portion. The frangible barrier portion may befrangible so as to be penetrable for opening said carrier to atmosphere.

According to another aspect of the present invention, there is providedan aerosol-generation apparatus for use in the system as described aboveand hereinafter.

According to another aspect of the present invention, there is provideda carrier for an aerosol precursor comprising: a housing for location ina receptacle of an aerosol-generating apparatus, said housing configuredto provide a fluid pathway between a first end that is disposed in fluidengagement with an inlet of said aerosol-generating apparatus and asecond end that is disposed in fluid engagement with an outlet of saidaerosol-generating apparatus; and a fluid-transfer article locatedwithin said housing, said fluid-transfer article comprising a firstregion for holding an aerosol precursor and for transferring saidaerosol precursor to an activation surface of a second region of saidarticle, said activation surface disposed at an end of said carrierconfigured for thermal interaction with a heater of anaerosol-generation apparatus; wherein said second region comprises atleast one discontinuity in said activation surface to form acorresponding at least one channel between said activation surface andan opposing surface through which heat is conveyable to said activationsurface from a heater, said at least one channel configured forproviding a fluid pathway across said activation surface, said fluidpathway across said activation surface forming a portion of said fluidpathway between said first end and said second end.

Optionally, the article may comprise a tubular member.

Optionally, said article may comprise a bore extending therethrough,said first region extending axially along an external surface of saidarticle and said second surface, located between said first region andsaid bore, extending axially along an internal surface of said article,said at least one discontinuity extending axially along said internalsurface of said article formed by said bore.

Optionally, said article may comprise a bore extending therethrough,said first region extending axially along an internal surface of saidarticle and said second surface extending axially along an externalsurface of said article, said at least one discontinuity extendingaxially at least partially along said external surface of said article.

Optionally, an end surface of said tubular member may comprise saidactivation surface and further wherein said at least one discontinuitymay extend radially across said activation surface.

Optionally, an end surface of said tubular member may comprise saidactivation surface and further wherein said at least one discontinuitymay extend linearly across said activation surface.

Optionally, an end surface of said tubular member may comprise saidactivation surface and further wherein said at least one discontinuitymay be convolute, meandering and/or serpentine across said activationsurface.

Optionally, said activation surface may be formed at an interfacebetween regions adjacent said at least one discontinuity and saidopposing surface through which heat is conveyed to said activationsurface from a heater.

Optionally, a thermally conductive barrier layer may be provided as saidopposing surface through which heat is conveyable to said activationsurface, said thermally conductive barrier layer configured for thermalcontact with a heater and locatable between a heater and said activationsurface of said article.

Optionally, said activation surface and said opposing surface throughwhich heat is conveyable to said activation surface may becomplementary. This may maintain a temperature gradient through the atleast one channel for consistency of activation.

Optionally, said article may be formed of a thermally conductivematerial.

Optionally, said article may be formed of a plastic material, such as,for example, Polyetherimide or Polytetrafluoroethylene (PTFE). Othersuitable materials may comprise, for example, BioVyon™ (by PorvairFiltration Group Ltd) and materials available from Porex®. Furtheroptionally, a substrate forming the fluid-transfer article may comprisepolypropylene or polyethylene terephthalate.

Optionally, said article may be formed from a hydrophilic material thatis configured to transfer fluid from said first region to said secondregion.

Optionally, said article may be formed from a sintered material.

Optionally, said article may comprise a plurality of regions havingdifferent structures.

Optionally, said article may be formed of a porous material in whichpore diameter in said first region is greater than pore diameter in saidsecond region.

Optionally, said article may be formed of a material that is of greaterhydrophilicity in said second region than said first region.

Optionally, said article may be formed of a wicking material comprisinga graduated wicking action.

Optionally, a first end and a second end of said housing may be sealedwith a removable end cap. The end caps are removable prior to thecarrier being located in said apparatus.

Optionally, a first end and a second end of said housing may be sealedwith a frangible barrier portion. The frangible barrier portion may befrangible so as to be penetrable for opening said carrier to atmosphere.

According to another aspect of the present invention, there is provideda fluid-transfer article comprising: a first region for holding anaerosol precursor and for transferring said aerosol precursor to anactivation surface of a second region of said article, said activationsurface disposed at an end of said article configured for thermalinteraction with a heater of an aerosol-generation apparatus; whereinsaid second region comprises at least one discontinuity in saidactivation surface to form a corresponding at least one channel betweensaid activation surface and an opposing surface through which heat isconveyable to said activation surface from a heater, said at least onechannel configured for providing a fluid pathway across said activationsurface, said fluid pathway across said activation surface forming aportion of said fluid pathway between said first end and said secondend.

Optionally, the article may comprise a tubular member.

Optionally, the article may comprise a bore extending therethrough, saidfirst region extending axially along an external surface of said articleand said second surface, located between said first region and saidbore, extending axially along an internal surface of said article, saidat least one discontinuity extending axially along said internal surfaceof said article formed by said bore.

Optionally, said article may comprise a bore extending therethrough,said first region extending axially along an internal surface of saidarticle and said second surface extending axially along an externalsurface of said article, said at least one discontinuity extendingaxially at least partially along said external surface of said article.

Optionally, an end surface of said tubular member may comprise saidactivation surface and further wherein said at least one discontinuitymay extend radially across said activation surface.

Optionally, an end surface of said tubular member may comprise saidactivation surface and further wherein said at least one discontinuitymay extend linearly across said activation surface.

Optionally, an end surface of said tubular member may comprise saidactivation surface and further wherein said at least one discontinuitymay be convolute, meandering and/or serpentine across said activationsurface.

Optionally, said activation surface may be formed at an interfacebetween regions adjacent said at least one discontinuity and saidopposing surface through which heat is conveyed to said activationsurface from a heater.

Optionally, a thermally conductive barrier layer may be provided as saidopposing surface through which heat is conveyable to said activationsurface, said thermally conductive barrier layer configured for thermalcontact with a heater and locatable between a heater and said activationsurface of said article.

Optionally, said activation surface and said opposing surface throughwhich heat is conveyable to said activation surface may becomplementary. This may maintain a temperature gradient through the atleast one channel for consistency of activation.

Optionally, said article may be formed of a thermally conductivematerial.

Optionally, said article may be formed of a plastic material, such as,for example, Polyetherimide or Polytetrafluoroethylene (PTFE). Othersuitable materials may comprise, for example, BioVyon™ (by PorvairFiltration Group Ltd) and materials available from Porex®. Furtheroptionally, a substrate forming the fluid-transfer article may comprisepolypropylene or polyethylene terephthalate.

Optionally, said article may be formed from a hydrophilic material thatis configured to transfer fluid from said first region to said secondregion.

Optionally, said article may be formed from a sintered material.

Optionally, said article may comprise a plurality of regions havingdifferent structures.

Optionally, said article may be formed of a porous material in whichpore diameter in said first region is greater than pore diameter in saidsecond region.

Optionally, said article may be formed of a material that is of greaterhydrophilicity in said second region than said first region.

Optionally, said article may be formed of a wicking material comprisinga graduated wicking action.

According to another aspect of the present invention, there is provideda kit-of-parts for assembling a system for aerosol delivery, comprising:an aerosol-generation apparatus comprising: a receptacle for receiving acarrier; a heater; a carrier for an aerosol precursor, said carrierlocatable in said receptacle, and said carrier comprising: a housing forlocation in said receptacle, said housing configured to provide a fluidpathway between a first end that is disposed in fluid engagement with aninlet of said aerosol-generating apparatus and a second end that isdisposed in fluid engagement with an outlet of said aerosol-generatingapparatus; and a fluid-transfer article located within said housing,said fluid-transfer article comprising a first region for holding anaerosol precursor and for transferring said aerosol precursor to anactivation surface of a second region of said article, said activationsurface disposed at an end of said carrier configured for thermalinteraction with a heater of said aerosol-generation apparatus; whereinsaid second region comprises at least one discontinuity in saidactivation surface to form a corresponding at least one channel betweensaid activation surface and an opposing surface through which heat isconveyable to said activation surface from said heater, said at leastone channel configured for providing a fluid pathway across saidactivation surface, said fluid pathway across said activation surfaceforming a portion of said fluid pathway between said first end and saidsecond end.

The invention includes the combination of the aspects and preferredfeatures described except where such a combination is clearlyimpermissible or expressly avoided.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

So that the invention may be more readily understood, and so thatfurther features thereof may be appreciated, embodiments of theinvention will now be described by way of example with reference to theaccompanying drawings in which:

FIG. 1 is a perspective view illustration of a system for aerosoldelivery according to one or more embodiments of the present invention;

FIG. 2 is a cross-sectional side view illustration of part of anapparatus of the system for aerosol delivery of FIG. 1;

FIG. 3 is a cross-sectional side view illustration of the system andapparatus for aerosol delivery of FIG. 1;

FIG. 4 is a perspective view illustration of an aerosol carrier for usein the system for aerosol delivery according to one or more embodimentsof the present invention;

FIG. 5 is a cross-section side view of elements of an aerosol carrierand of part of an apparatus of the system for aerosol delivery accordingto one or more embodiments of the present invention;

FIG. 6 is a cross-section side view of elements of an aerosol carrierand of part of an apparatus of the system for aerosol delivery accordingto one or more embodiments of the present invention;

FIG. 7 is a perspective view illustration of the aerosol carrier and ofpart of an apparatus of the system for aerosol delivery according to oneor more embodiments of the present invention;

FIG. 8 is a perspective view illustration of the aerosol carrier and ofpart of an apparatus of the system for aerosol delivery according to oneor more embodiments of the present invention;

FIG. 9 is a perspective end view illustration of a fluid-transferarticle of the aerosol carrier according to one or more embodiments ofthe present invention;

FIG. 10 is a perspective end view illustration of a fluid-transferarticle of the aerosol carried according to one or more embodiments ofthe present invention;

FIG. 11 is a cross-section side view of an aerosol carrier according toone or more embodiments of the present invention;

FIG. 12 is a perspective cross-section side view of the aerosol carrierof FIG. 11;

FIG. 13 is an exploded perspective view illustration of a kit-of-partsfor assembling a system according to one or more embodiments of thepresent invention;

FIG. 14 is a cross-section side view of elements of an aerosol carrierand of part of an apparatus of the system for aerosol delivery accordingto one or more embodiments of the present invention;

FIG. 15 is a cross-section view of elements of an aerosol carrier and ofpart of an apparatus of the system for aerosol delivery according to oneor more embodiments of the present invention;

FIG. 16 is a perspective view of a fluid-transfer article of the systemfor aerosol delivery according to one or more embodiments of the presentinvention;

FIG. 17 is a cross-section view of elements of an aerosol carrier and ofpart of an apparatus of the system for aerosol delivery according to oneor more embodiments of the present invention; and

FIG. 18 is a cross-section view of elements of an aerosol carrier and ofpart of an apparatus of the system for aerosol delivery according to oneor more embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Aspects and embodiments of the present invention will now be discussedwith reference to the accompanying figures. Further aspects andembodiments will be apparent to those skilled in the art. All documentsmentioned in this text are incorporated herein by reference.

In general outline, one or more embodiments in accordance with thepresent invention may provide a system for aerosol delivery in which anaerosol carrier may be inserted into a receptacle (e.g. a “heatingchamber”) of an apparatus for initiating and maintaining release of anaerosol from the aerosol carrier. Another end, or another end portion,of the aerosol carrier may protrude from the apparatus and can beinserted into the mouth of a user for the inhalation of aerosol releasedfrom the aerosol carrier cartridge during operation of the apparatus.

Hereinafter, and for convenience only, “system for aerosol delivery”shall be referred to as “aerosol delivery system”.

Referring now to FIG. 1, there is illustrated a perspective view of anaerosol delivery system 10 comprising an aerosol generation apparatus 12operative to initiate and maintain release of aerosol from afluid-transfer article in an aerosol carrier 14. In the arrangement ofFIG. 1, the aerosol carrier 14 is shown with a first end 16 thereof anda portion of the length of the aerosol carrier 14 located within areceptacle of the apparatus 12. A remaining portion of the aerosolcarrier 14 extends out of the receptacle. This remaining portion of theaerosol carrier 14, terminating at a second end 18 of the aerosolcarrier, is configured for insertion into a user's mouth. A vapourand/or aerosol is produced when a heater (not shown in FIG. 1) of theapparatus 12 heats a fluid-transfer article in the aerosol carrier 14 torelease a vapour and/or an aerosol, and this can be delivered to theuser, when the user sucks or inhales, via a fluid passage incommunication with an outlet of the aerosol carrier 14 from thefluid-transfer article to the second end 18.

The apparatus 12 also comprises air-intake apertures 20 in the housingof the apparatus 12 to provide a passage for air to be drawn into theinterior of the apparatus 12 (when the user sucks or inhales) fordelivery to the first end 16 of the aerosol carrier 14, so that the aircan be drawn across an activation surface of a fluid-transfer articlelocated within a housing of the aerosol carrier 14 during use.Optionally, these apertures may be perforations in the housing of theapparatus 12.

A fluid-transfer article (not shown in FIG. 1, but described hereinafterwith reference to FIGS. 5, 6, 7, 8, 9, 10, 11 and 12) is located withina housing of the aerosol carrier 14. The fluid-transfer article containsan aerosol precursor material, which may include at least one of:nicotine; a nicotine precursor material; a nicotine compound; and one ormore flavourings. The fluid-transfer article is located within thehousing of the aerosol carrier 14 to allow air drawn into the aerosolcarrier 14 at, or proximal, the first end 16 to flow across anactivation surface of the fluid-transfer article. As air passes acrossthe activation surface of the fluid-transfer article, an aerosol may beentrained in the air stream from a substrate forming the fluid-transferarticle, e.g. via diffusion from the substrate to the air stream and/orvia vaporisation of the aerosol precursor material and release from thefluid-transfer article under heating.

The substrate forming the fluid-transfer article 34 comprises a porousmaterial where pores of the porous material hold, contain, carry, orbear the aerosol precursor material. In particular, the porous materialof the fluid-transfer article may be a polymeric wicking material suchas, for example, a sintered material. Particular examples of materialsuitable for the fluid-transfer article include: Polyetherimide (PEI);Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK); Polyimide(PI); Polyethersulphone (PES); and Ultra-High Molecular WeightPolyethylene. Other suitable materials may comprise, for example,BioVyon™ (by Porvair Filtration Group Ltd) and materials available fromPorex®. Further optionally, a substrate forming the fluid-transferarticle may comprise Polypropylene (PP) or Polyethylene Terephthalate(PET). All such materials may be described as heat resistant polymericwicking material in the context of the present invention.

The aerosol carrier 14 is removable from the apparatus 12 so that it maybe disposed of when expired. After removal of a used aerosol carrier 14,a replacement aerosol carrier 14 can be inserted into the apparatus 12to replace the used aerosol carrier 14.

FIG. 2 is a cross-sectional side view illustration of a part ofapparatus 12 of the aerosol delivery system 10. The apparatus 12comprises a receptacle 22 in which is located a portion of the aerosolcarrier 14. In one or more optional arrangements, the receptacle 22 mayenclose the aerosol carrier 14. The apparatus 12 also comprise a heater24, which opposes an activation surface of the fluid-transfer article(not shown in FIG. 2) of the aerosol carrier 14 when an aerosol carrier14 is located within the receptacle 22.

Air flows into the apparatus 12 (in particular, into a closed end of thereceptacle 22) via air-intake apertures 20. From the closed end of thereceptacle 22, the air is drawn into the aerosol carrier 14 (under theaction of the user inhaling or sucking on the second end 18) andexpelled at the second end 18. As the air flows into the aerosol carrier14, it passes across the activation surface of the fluid-transferarticle. Heat from the heater 24, which opposes the activation surfaceof the fluid-transfer article, causes vaporisation of aerosol precursormaterial at the activation surface of the fluid-transfer article and anaerosol is created in the air flowing over the activation surface. Thus,through the application of heat in the region of the activation surfaceof the fluid-transfer article, an aerosol is released, or liberated,from the fluid-transfer article, and is drawn from the material of theaerosol carrier unit by the air flowing across the activation surfaceand is transported in the air flow to via outlet conduits (not shown inFIG. 2) in the housing of the aerosol carrier 14 to the second end 18.The direction of air flow is illustrated by arrows in FIG. 2.

To achieve release of the captive aerosol from the fluid-transferarticle, the fluid-transfer article of the aerosol carrier 14 is heatedby the heater 24. As a user sucks or inhales on second end 18 of theaerosol carrier 14, the aerosol released from the fluid-transfer articleand entrained in the air flowing across the activation surface of thefluid-transfer article is drawn through the outlet conduits (not shown)in the housing of the aerosol carrier 14 towards the second end 18 andonwards into the user's mouth.

Turning now to FIG. 3, a cross-sectional side view of the aerosoldelivery system 10 is schematically illustrated showing the featuresdescribed above in relation to FIGS. 1 and 2 in more detail.

As can be seen, apparatus 12 comprises a housing 26, in which arelocated the receptacle 22 and heater 24. The housing 26 also containscontrol circuitry (not shown) operative by a user, or upon detection ofair and/or vapour being drawn into the apparatus 12 through air-intakeapertures 20, i.e. when the user sucks or inhales. Additionally, thehousing 26 comprises an electrical energy supply 28, for example abattery. Optionally, the battery comprises a rechargeable lithium ionbattery. The housing 26 also comprises a coupling 30 for electrically(and optionally mechanically) coupling the electrical energy supply 28to control circuitry (not shown) for powering and controlling operationof the heater 24.

Responsive to activation of the control circuitry of apparatus 12, theheater 24 heats the fluid-transfer article (not shown in FIG. 3) ofaerosol carrier 14. This heating process initiates (and, throughcontinued operation, maintains) release of vapour and/or an aerosol fromthe activation surface of the fluid-transfer article. The vapour and/oraerosol formed as a result of the heating process is entrained into astream of air being drawn across the activation surface of thefluid-transfer article (as the user sucks or inhales). The stream of airwith the entrained vapour and/or aerosol passes through the aerosolcarrier 14 via outlet conduits (not shown) and exits the aerosol carrier14 at second end 18 for delivery to the user.

This process is briefly described above in relation to FIG. 2, wherearrows schematically denote the flow of the air stream into theapparatus 12 and through the aerosol carrier 14, and the flow of the airstream with the entrained vapour and/or aerosol through the aerosolcarrier 14.

FIGS. 4 to 6 schematically illustrate the aerosol carrier 14 in moredetail (and, in FIGS. 5 and 6, features within the receptacle in moredetail). FIG. 4 illustrates an exterior of the aerosol carrier 14, FIG.5 illustrates internal components of the aerosol carrier 14 in anoptional arrangement, and FIG. 6 illustrates internal components of theaerosol carrier 14 in another optional arrangement.

FIG. 4 illustrates the exterior of the aerosol carrier 14, whichcomprises a housing 32 for housing said fluid-transfer article (notshown) and at least one other internal component. The particular housing32 illustrated in FIG. 4 comprises a tubular member, which may begenerally cylindrical in form, and which is configured to be receivedwithin the receptacle of the apparatus. First end 16 of the aerosolcarrier 14 is for location to oppose the heater of the apparatus, andsecond end 18 (and the region adjacent the second end 18) is configuredfor insertion into a user's mouth.

FIG. 5 illustrates some internal components of the aerosol carrier 14and of the heater 24 of apparatus 12.

As described above, the aerosol carrier 14 comprises a fluid-transferarticle 34. The aerosol carrier 14 optionally may comprise a conductionelement 36 (as shown in FIG. 5). In one or more arrangements, theaerosol carrier 14 is located within the receptacle of the apparatussuch that the activation surface of the fluid-transfer article opposesthe heater of the apparatus and receives heat directly from the heaterof the apparatus. In an optional arrangement, such as illustrated inFIG. 5 for example, the aerosol carrier 14 comprises a conductionelement 36.

When aerosol carrier 14 is located within the receptacle of theapparatus such that the activation surface of the fluid-transfer articleis located to oppose the heater of the apparatus, the conduction elementis disposed between the heater 24 and the activation surface of thefluid-transfer article. Heat may be transferred to the activationsurface via conduction through conduction element 36 (i.e. applicationof heat to the activation surface is indirect).

Further components not shown in FIGS. 5 and 6 (see FIGS. 11 and 12)comprise: an inlet conduit, via which air can be drawn into the aerosolcarrier 14; an outlet conduit, via which an air stream entrained withaerosol can be drawn from the aerosol carrier 14; a filter element; anda reservoir for storing aerosol precursor material and for providing theaerosol precursor material to the fluid-transfer article 34.

In FIGS. 5 and 6, aerosol carrier is shown as comprising thefluid-transfer article 34 located within housing 32. The materialforming the fluid-transfer article 34 comprises a porous structure,where pore diameter size varies between one end of the fluid-transferarticle 34 and another end of the fluid-transfer article 34. In theillustrative examples of FIGS. 5 and 6, the pore diameter size graduallydecreases from a first end remote from heater 24 (the upper end as shownin the figure) to a second end proximal heater 24 (the lower end asshown in the figure). Although the figure illustrates the pore diametersize changing in a step-wise manner from the first to the second end(i.e. a first region with pores having a diameter of a first size, asecond region with pores having a diameter of a second, smaller size,and a third region with pores having a diameter of a third, yet smallersize), the change in pore size from the first end to the second end maybe gradual rather than step-wise. This configuration of pores having adecreasing diameter size from the first end and second end can provide awicking effect, which can serve to draw fluid from the first end to thesecond end of the fluid-transfer article 34.

The fluid-transfer article 34 comprises a first region 34 a for holdingan aerosol precursor. In one or more arrangements, the first region 34 aof the fluid-transfer article 34 comprises a reservoir for holding theaerosol precursor. The first region 34 a can be the sole reservoir ofthe aerosol carrier 14, or it can be arranged in fluid communicationwith a separate reservoir, where aerosol precursor is stored for supplyto the first region 34 a.

The fluid-transfer article 34 also comprises a second region 34 b.Aerosol precursor is drawn from the first region 34 a to the secondregion 34 b by the wicking effect of the substrate material forming thefluid-transfer article. Thus, the first region 34 a is configured totransfer the aerosol precursor to the second region 34 b of the article34.

At the second end of fluid-transfer article 34, the surface of thesecond region 34 b defines an activation surface 38, which is disposedopposite a surface for conveying heat to the activation surface 38. Inthe illustrative examples of FIGS. 5 and 6, the opposing surface forconveying heat to the activation surface 38 comprises a conductionelement 36. The conduction element 36 is located for thermal interactionwith heater 24 and is arranged to transfer heat from heater 24 to theactivation surface 38. As noted above, however, the conduction element36 may be absent in some arrangements, in which case the activationsurface 38 is disposed to receive heat directly from heater 24.

The conduction element 36, if present, may comprise a thin film ofthermally conductive material, such as, for example, a metal foil (forexample, aluminium, brass, copper, gold, steel, silver, or an alloycomprising anyone of the foregoing together with thermally conductiveplastics and/or ceramics).

The activation surface 38 is discontinuous such that at least onechannel 40 is formed between the activation surface 38 and theconduction element 36 (or the heater 24 in the case of arrangements inwhich the conduction element 36 is absent). In some arrangements, thediscontinuities may be such that the activation surface 38 isundulating.

In the illustrative examples of FIGS. 5 and 6, the activation surface 38comprises a plurality of grooves or valleys therein to form anundulating surface, the grooves or valleys being disposed in a parallelarrangement across the activation surface 38. Thus, there are aplurality of channels 40 between the activation surface 38 and theconduction element 36.

In the illustrative example of FIG. 5, the grooves or valleys in theactivation surface 38 provide alternating peaks and troughs that giverise to a “saw-tooth” type profile. In one or more optionalarrangements, the activation surface may comprise a “castellated” typeprofile (i.e. a “square wave” type profile), for example, such asillustrated in the example of FIG. 6. In one or more optionalarrangements, the activation surface may comprise a “sinusoidal” typeprofile. The profile may comprise a mixture of two or more of the aboveprofiles given as illustrative examples.

In the illustrative examples of FIGS. 5 and 6, the first region 34 a ofthe fluid-transfer article 34 is located at an “upstream” end of thefluid-transfer article 34 and the second region 34 b is located at adownstream” end of the fluid-transfer article 34. That is, aerosolprecursor is wicked, or is drawn, from the “upstream” end of thefluid-transfer article 34 to the “downstream” end of the fluid-transferarticle 34 (as denoted by arrow A in FIG. 5).

The aerosol precursor is configured to release an aerosol and/or vapourupon heating. Thus, when the activation surface 38 receives heatconveyed from heater 24, the aerosol precursor held at the activationsurface 38 is heated. The aerosol precursor, which is captively held inmaterial of the fluid-transfer article at the activation surface 38 isreleased into an air stream flowing through the channels 40 between theconduction element 36 and activation surface 38 (or between the heater24 and the activation surface 38) as an aerosol and/or vapour.

The shape and/or configuration of the activation surface 38 and theassociated shape(s) and/or configuration(s) of the one or more channels40 formed between the activation surface 38 and conduction element 36(or between the activation surface 38 and heater 24) permit air to flowacross the activation surface 38 (through the one or more channels 40)and also increase the surface area of the activation surface 38 of thefluid-transfer article 34 that is available for contact with a flow ofair across the activation surface 38.

FIGS. 7 and 8 show perspective view illustrations of the fluid-transferarticle 34 of aerosol carrier and a heater 24 of the apparatus of thesystem for aerosol delivery. In particular, these figures illustrate airflows across the activation surface 38 when the apparatus is in use in afirst arrangement of the fluid-transfer article 34 (see FIG. 7), and ina second arrangement of the fluid-transfer article 34 (see FIG. 8).

In the illustrated example of use of the apparatus schematicallyillustrated in FIG. 7, when a user sucks on a mouthpiece of theapparatus, air is drawn into the carrier through inlet apertures (notshown) provided in a housing of the carrier. An incoming air stream 42is directed to the activation surface 38 of the fluid-transfer article34 (e.g. via a fluid communication pathway within the housing of thecarrier). When the incoming air stream 42 reaches a first side of theactivation surface 38, the incoming air stream 42 flows across theactivation surface 38 via the one or more channels 40 formed between theactivation surface 38 and the conduction element 36 (or between theactivation surface 38 and heater 24). The air stream 44 flowing throughthe one or more channels 40 is denoted by a dashed line in FIG. 7. Asthe air stream 44 flows through the one or more channels 40, aerosolprecursor at activation surface 38, across which the air stream 44flows, is released from the activation surface 38 by heat conveyed tothe activation surface from the heater 24. Aerosol precursor releasedfrom the activation surface 38 in this manner is then entrained in theair stream 44 flowing through the one or more channels 40. In use, theheater 24 of the apparatus 12 conveys heat to the fluid-transfer article34 to raise the temperature of the activation surface 38 to a sufficienttemperature to release, or liberate, captive substances (i.e. theaerosol precursor) held at the activation surface 38 of thefluid-transfer article 34 to form a vapour and/or aerosol, which isdrawn downstream across the activation surface 38 of the fluid-transferarticle. As the air stream 44 continues its passage in the one or morechannels 40, more released aerosol precursor is entrained within the airstream 44. When the air stream 44 entrained with aerosol precursor exitsthe one or more channels 40 at a second side of the activation surface38, it is directed to an outlet, from where it can be inhaled by theuser via a mouthpiece. An outgoing air stream 46 entrained with aerosolprecursor is directed to the outlet (e.g. via a fluid communicationpathway within the housing of the carrier).

Therefore, operation of the apparatus will cause heat from the heater 24to be conveyed to the activation surface 38 of the fluid-transferarticle. At a sufficiently high temperature, captive substances held atthe activation surface 38 of the fluid-transfer article 34 are released,or liberated, to form a vapour and/or aerosol. Thus, when a user drawson a mouthpiece of the apparatus, the released substances from thefluid-transfer article are drawn away from the activation surface 38(entrained in a stream of air) and condense to form an aerosol that isdrawn through the a gas communication pathway for delivery to an outlet,which is in fluid communication with the mouthpiece.

As the aerosol precursor is released from the activation surface 38, awicking effect of the fluid-transfer article 34 causes aerosol precursorwithin the body of the fluid-transfer article to migrate to theactivation surface 38 to replace the aerosol precursor released from theactivation surface 38 into air stream 44.

Operation of the heater 24 is controlled by control circuitry (notshown), which is operable to actuate the heater 24 responsive to anactuation signal from a switch operable by a user or configured todetect when the user draws air through a mouthpiece of the apparatus bysucking or inhaling. In an optional arrangement, the control circuitryoperates to actuate the heater 24 with as little delay as possible fromreceipt of the actuation signal from the switch, or detection of theuser drawing air through the mouthpiece. This may effect nearinstantaneous heating of the activation surface 38 of the fluid-transferarticle 34.

In the illustrated example of use of the apparatus schematicallyillustrated in FIG. 8, rather than the case of FIG. 7, where air isdrawn toward the activation surface 38 from one side only (and exitsfrom the one or more channels 40 at an opposite side), a gascommunication pathway for an incoming air stream is configured todeliver the incoming air stream to the activation surface 38 from bothsides of the fluid-transfer article, and thus from both ends of thechannels 40 formed therein. In such an arrangement, a gas communicationpathway for an outlet airstream may be provided through the body of thefluid-transfer article 34. An outlet fluid communication pathway for anoutlet airstream in the illustrative example of FIG. 8 is denoted byreference number 48.

Thus, in the illustrative example of FIG. 8, when a user draws on amouthpiece of the apparatus, air is drawn into the aerosol carrier 14through inlet apertures (not shown) provided in a housing of thecarrier. An incoming air stream 42 a from a first side is directed to afirst side of the activation surface 38 of the fluid-transfer article 34(e.g. via a gas communication pathway within the housing of the aerosolcarrier 14). An incoming air stream 42 b from a second side is directedto a second side of the activation surface 38 of the fluid-transferarticle 34 (e.g. via a gas communication pathway within the housing ofthe aerosol carrier 14). When the incoming air stream 42 a from thefirst side reaches the first side of the activation surface 38, theincoming air stream 42 a flows across the activation surface 38 via theone or more channels 40 formed between the activation surface 38 and theconduction element 36 (or between the activation surface 38 and heater24). Likewise, when the incoming air stream 42 b from the second sidereaches the second side of the activation surface 38, the incoming airstream 42 b flows across the activation surface 38 via the one or morechannels 40 formed between the activation surface 38 and the conductionelement 36 (or between the activation surface 38 and heater 24). The airstreams 44 a and 44 b from each side flowing through the one or morechannels 40 are denoted by dashed lines in FIG. 8. As air streams 44 aand 44 b flow through the one or more channels 40, aerosol precursor inthe activation surface 38, across which the air streams 44 a and 44 bflow, is released from the activation surface 38 by heat conveyed to theactivation surface from the heater 24. Aerosol precursor released fromthe activation surface 38 is entrained in air streams 44 a and 44 bflowing through the one or more channels 40. In use, the heater 24 ofthe apparatus 12 conveys heat to the fluid-transfer article 34 to raisea temperature of the activation surface 38 to a sufficient temperatureto release, or liberate, captive substances (i.e. the aerosol precursor)held at the activation surface 38 of the fluid-transfer article 34 toform a vapour and/or aerosol, which is drawn downstream across theactivation surface 38 of the fluid-transfer article. As the air streams44 a and 44 b continue their passages in the one or more channels 40,more released aerosol precursor is entrained within the air streams 44 aand 44 b. When the air streams 44 a and 44 b entrained with aerosolprecursor meet at a mouth of the outlet fluid communication pathway 48,they enter the outlet fluid communication pathway 48 and continue untilthey exit outlet fluid communication pathway 48, either as a singleoutgoing air stream 46 (as shown), or as separate outgoing air streams.The outgoing air stream 46 is directed to an outlet, from where it canbe inhaled by the user via a mouthpiece. The outgoing air stream 46entrained with aerosol precursor is directed to the outlet (e.g. via agas communication pathway within the housing of the aerosol carrier 14).

FIGS. 9 and 10 are perspective end view illustrations of afluid-transfer article 34 of the aerosol carrier according to one ormore arrangements. These figures show different types of channelconfigurations as illustrative examples. In both illustrative examplesof a channel configuration, as shown in FIGS. 9 and 10, thefluid-transfer article 34 comprises a cylindrical member, whichcomprises a central bore extending therethrough for fluid communicationbetween the activation surface 38 and an outlet, from where an outgoingair stream can be delivered for inhalation. The central bore serves asan outlet fluid communication pathway 48 (e.g. as described above inrelation to FIG. 9).

In both illustrative examples of FIGS. 9 and 10, an incoming air stream42 is directed to a mouth of a channel 40 formed between the activationsurface 38 of the fluid-transfer article 34 and conduction element (notshown), or between the activation surface 38 and a heater (not shown).In both illustrative examples of FIGS. 9 and 10, the mouth of thechannel 40 is located at an outer edge of the fluid-transfer article 34and an exit from the channel 40 (in fluid communication with the outletfluid communication pathway 48) is located toward a centre of thefluid-transfer article. Therefore, the incoming air stream 42 enters thechannel 40 via channel mouth at the outer edge of the fluid-transferarticle 34 and moves toward the centre of the fluid-transfer article 34as directed by the channel 40. As described above, as the air streampasses across activation surface 38 through channel 40, aerosolprecursor is released from the activation surface 38 and is entrained inair stream 44. Air stream 44 continues to flow through the channel 40until it reaches an exit thereof, from where it enters the outlet fluidcommunication pathway 48 and proceeds as an outgoing air stream 46entrained with aerosol precursor toward the outlet.

In both illustrative examples of FIGS. 9 and 10, the valleys or groovesof the activation surface 38 that form part of the channel 40 arearranged to define a circuitous route 20 across the activation surface.In the illustrative examples, the route is a spiral path, but inoptional arrangements, may be meandering or circuitous in some othermanner. In optional arrangements, the activation surface may be locatedto face outwardly from the cylinder, such that the groove(s) orvalley(s) may be in the outer surface of the cylinder forming thefluid-transfer article. These grooves or valleys may be arranged inparallel in a direction along the length of the cylinder. The groove(s)or valley(s) may be arranged in a spiral manner around the outside ofthe cylinder. In optional arrangements, the activation surface 38 may belocated to face inwardly from the cylinder (i.e. surrounding the centralbore), such that the groove(s) or valley(s) may be in the inner surfaceof the cylinder forming the fluid-transfer article 34. These grooves orvalleys may be arranged in parallel in a direction along the length ofthe cylinder. The groove(s) or valley(s) may be arranged in a spiralmanner around the inside of the cylinder.

FIGS. 11 and 12 illustrate an aerosol carrier 14 according to one ormore possible arrangements in more detail. FIG. 11 is a cross-sectionside view illustration of the aerosol carrier 14 and FIG. 12 is aperspective cross-section side view illustration of the aerosol carrier14 of FIG. 11.

As can be seen from FIGS. 11 and 12, the aerosol carrier 14 is generallytubular in form. The aerosol carrier 14 comprises housing 32, whichdefines the external walls of the aerosol carrier 14 and which definestherein a chamber in which are disposed the fluid-transfer article 34(adjacent the first end 16 of the aerosol carrier 14) and internal wallsdefining the outlet fluid communication pathway 48. Outlet fluidcommunication pathway 48 defines a fluid pathway for an outgoing airstream from the channels 40 to the second end 18 of the aerosol carrier14. In the examples illustrated in FIGS. 11 and 12, the fluid-transferarticle 34 is an annular shaped element located around the outlet fluidcommunication pathway 48.

In walls of the housing 32, there are provided inlet apertures 50 toprovide a fluid communication pathway for an incoming air stream toreach the fluid-transfer article 34, and particularly the one or morechannels 40 defined between the activation surface of the fluid-transferarticle 34 and the conduction element 36 (or between the activationsurface and the 15 heater).

In the illustrated example of FIGS. 11 and 12, the aerosol carrier 14further comprises a filter element 52. The filter element 52 is locatedacross the outlet fluid communication pathway 48 such that an outgoingair stream passing through the outlet fluid communication pathway 48passes through the filter element 52.

With reference to FIG. 12, when a user sucks on a mouthpiece of theapparatus (or on the second end 18 of the aerosol carrier 14, ifconfigured as a mouthpiece), air is drawn into the carrier through inletapertures 50 extending through walls in the housing 32 of the aerosolcarrier 14. An incoming air stream 42 a from a first side of the aerosolcarrier 14 is directed to a first side of the activation surface 38 ofthe fluid-transfer article 34 (e.g. via a gas communication pathwaywithin the housing of the carrier). An incoming air stream 42 b from asecond side of the aerosol carrier 14 is directed to a second side ofthe activation surface 38 of the fluid-transfer article 34 (e.g. via agas communication pathway within the housing of the carrier). When theincoming air stream 42 a from the first side of the aerosol carrier 14reaches the first side of the activation surface 38, the incoming airstream 42 a from the first side of the aerosol carrier 14 flows acrossthe activation surface 38 via the one or more channels 40 formed betweenthe activation surface 38 and the conduction element 36 (or between theactivation surface 38 and heater 24). Likewise, when the incoming airstream 42 b from the second side of the aerosol carrier 14 reaches thesecond side of the activation surface 38, the incoming air stream 42 bfrom the second side of the aerosol carrier 14 flows across theactivation surface 38 via the one or more channels 40 formed between theactivation surface 38 and the conduction element 36 (or between theactivation surface 38 and heater 24). The air streams 44 a and 44 b fromeach side flowing through the one or more channels 40 are denoted bydashed lines in FIG. 12. As air streams 44 a and 44 b flow through theone or more channels 40, aerosol precursor in the activation surface 38,across which the air streams 44 a and 44 b flow, is released from theactivation surface 38 by heat conveyed to the activation surface fromthe heater 24. Aerosol precursor released from the activation surface 38is entrained in air streams 44 a and 44 b flowing through the one ormore channels 40. In use, the heater 24 of the apparatus 12 conveys heatto the activation surface 38 of the fluid-transfer article 34 to raise atemperature of the activation surface 38 to a sufficient temperature torelease, or liberate, captive substances (i.e. the aerosol precursor)held at the activation surface 38 of the fluid-transfer article 34 toform a vapour and/or aerosol, which is drawn downstream across theactivation surface 38 of the fluid-transfer article 34. As the airstreams 44 a and 44 b continue their passages in the one or morechannels 40, more released aerosol precursor is entrained within the airstreams 44 a and 44 b. When the air streams 44 a and 44 b entrained withaerosol precursor meet at a mouth of the outlet fluid communicationpathway 48, they enter the outlet fluid communication pathway 48 andcontinue until they pass through filter element 52 and exit outlet fluidcommunication pathway 48, either as a single outgoing air stream, or asseparate outgoing air streams 46 (as shown). The outgoing air streams 46are directed to an outlet, from where it can be inhaled by the userdirectly (if the second end 18 of the aerosol capsule 14 is configuredas a mouthpiece), or via a mouthpiece. The outgoing air streams 46entrained with aerosol precursor are directed to the outlet (e.g. via agas communication pathway within the housing of the carrier).

When the user initially draws on a mouthpiece of the apparatus (or onethe second end 18 of the aerosol carrier 14, if configured as amouthpiece), this will cause an air column located in the outlet fluidcommunication pathway 48 to move towards the outlet. In turn, this willdraw air into the fluid communication pathway from the one or morechannels 40. This will cause a pressure drop in the channels 40. Toequalise the pressure in the channels 40, air will be drawn into theaerosol carrier 14, and thus into the channels 40 via the inletapertures 50. During the period of lower pressure in the one or morechannels 40 when the user begins to draw, aerosol precursor in thefluid-transfer medium will be released into the channels from theactivation surface 38, because the aerosol precursor is drawn into theone or more channels by way of the lower pressure. This effect is inaddition to the effect of releasing the aerosol precursor from theactivation surface 38 by way of heat conveyed from the heater. Thedrawing of the aerosol precursor from the activation surface 38 by wayof the user sucking on the mouthpiece of the apparatus (or one thesecond end 18 of the aerosol carrier 14, if configured as a mouthpiece)may produce a dragging effect on the volumetric rate of flow experiencedby the user during a suction action, i.e. the user may have to suckharder to achieve a same volumetric rate of flow. This effect maymanifest itself as a similar physical sensation experienced by the useras those experienced from a traditional smoking or tobacco product.

FIG. 13 is an exploded perspective view illustration of a kit-of-partsfor assembling an aerosol delivery system 10.

As will be appreciated, in the arrangements described above, thefluid-transfer article 34 is provided within a housing 32 of the aerosolcarrier 14. In such arrangements, the housing of the aerosol carrier 14serves to protect the fluid-transfer article 34, whilst also allowingthe aerosol carrier 14 to be handled by a user without his/her fingerscoming into contact with the aerosol precursor liquid retained therein.In such arrangements, it will be appreciated that the aerosol carrier 14has a multi-part construction. In some cases this might be consideredsomewhat disadvantageous because it requires a relatively complicatedassembly procedure which can be both time-consuming and expensive.Turning now to consider FIG. 14, there is illustrated another possibleaspect of the fluid-transfer article 34, which may be employed in somearrangements, and which may permit the creation of a significantlysimplified aerosol carrier 14.

FIG. 14 illustrates an alternative fluid-transfer article 34 in positionadjacent a planar heater 24, such that the air flow channels 40 arepositioned between the activation surface 38 and the heater 24. In thearrangement of FIG. 14, the substrate forming the fluid-transfer article34 again comprises a porous material where pores of the porous materialhold, contain, carry, or bear the aerosol precursor material. It isenvisaged, for example, that the same types of substrate material may beused in the arrangement illustrated in FIG. 14 as in thepreviously-described arrangements. In particular, therefore, the porousmaterial of the fluid-transfer article 34 may be a polymeric wickingmaterial. However, in the arrangement illustrated in FIG. 14, thesubstrate material includes an integrally formed peripheral wall 54.

It is proposed that the peripheral wall 54 may be formed by treating theoutermost surface of the porous substrate material of the fluid-transferarticle 34 so as to render the surface substantially liquid-impermeable.For example, it is envisaged that in some arrangements the substratematerial may be locally heated so as to fuse the material and close upits internal pores in the localised region of the surface.Alternatively, it is envisaged that the substrate material may betreated by a sintering process in order to create the liquid-impermeableperipheral wall 54. The peripheral wall 54 may alternatively be createdby a chemical treatment process to render the substrate materialsubstantially liquid-impermeable in the region of its outermost surface.As will therefore be appreciated, the peripheral wall 54 may beconsidered to take the form of a skin formed from the material of thesubstrate itself.

The peripheral wall may be created in this manner so as to substantiallycompletely circumscribe the substrate material. It is to be appreciated,however, that the activation surface 38 of the fluid-transfer article 34will not be treated in this manner, thereby ensuring that it will retainthe function described above in detail in cooperation with the heater24. The thickness of the peripheral wall 54 formed from the substratemay vary depending on the desired physical properties of thefluid-transfer article 34. For example, a relatively thin peripheralwall 54 might be desirable in some circumstances, as this may retainsome flexibility in the material, thereby providing a fluid-transferarticle which will feel soft in the hands of a user. Alternatively, arelatively thick peripheral wall 54 might be desirable in arrangementswhere the peripheral wall 54 is required to provide some structuralrigidity to the fluid-transfer article 34. The peripheral wall 54 maytherefore have a thickness of less than 3 mm; or less than 2.5 mm; orless than 2 mm; or less than 1.5 mm; or less than 1 mm; or less than 0.9mm; or less than 0.8 mm; or less than 0.7 mm; or less than 0.6 mm; orless than 0.5 mm; or less than 0.4 mm; or less than 0.3 mm; or less than0.2 mm; or less than 0.1 mm in some embodiments.

As will be appreciated, the liquid-impermeable nature of the resultingperipheral wall or skin means that the fluid-transfer article 34 may behandled by a user without getting his or her fingers wet from theaerosol precursor liquid retained therein. This opens up the possibilityof the fluid-transfer article 34 being used without an enclosing housing32, as was necessary in the previously-described arrangements. It istherefore envisaged that in some arrangements, the fluid-transferarticle 34 may itself define an entire aerosol carrier 14. Furthermore,it is envisaged that in some embodiments, a fluid-transfer article 34 inaccordance with this proposal may be provided in the form of a unitarymonolithic element of substrate material and could, therefore, take theform of a single-piece consumable or aerosol carrier 14 for anaerosol-delivery system 10, which may be provided pre-filled withaerosol precursor liquid and which may be discarded when the initialvolume of precursor has been used. A single-piece consumable of thistype offers very significant advantages in terms of cost of manufacture,and from an environmental point of view.

Turning now to consider FIG. 15, there is illustrated a fluid-transferarticle 34 in combination with a heater 24. The fluid-transfer article34 may have a peripheral wall or skin formed in the manner describedabove, although this is not essential and indeed is not present in theparticular arrangement illustrated in FIG. 15. The particular feature ofthe fluid-transfer article 34 illustrated in FIG. 15 which is ofrelevance is the cross-sectional profile of the channels 40 defined inthe activation surface 38 of the second region 34 b of the article. Aswill be noted, the channels 40 visible in FIG. 15 have a significantlydifferent profile to the “saw-tooth” type profile illustrated in FIG. 5,and to the “castellated” type profile illustrated in FIG. 6.Nevertheless, as will be explained, the channel profile illustrated inFIG. 15 shares a characteristic with the “saw-tooth” type profileillustrated in FIG. 5.

The fluid-transfer article 34 is illustrated in FIG. 15 such that itsactivation surface 38 of the second region 34 b is in direct engagementwith a heating surface 55 of the heater 24. In the arrangementillustrated, the heater 24 may comprise a heater substrate defining asubstantially planar heating surface, and may have a plurality ofsubstantially parallel elongate heating elements 56 in the form oftracks or filaments formed on the heating surface 55, for example byprinting or a convenient form of deposition. The heating elements 56 maycomprise, for example, resistive heating filaments. They are arranged soas to extend generally parallel with the channels 40, with two suchheating elements 56 being aligned with and located within each channel40 when the fluid-transfer article 34 and the heater 24 are interengagedas illustrated.

The activation surface 38 of the arrangement of FIG. 15 is discontinuousin a manner such that it includes a plurality of spaced-apart angledsurface portions 57, each of which is arranged to form an acuteintersection angle 58 with the heating surface 55. The angled surfaceportions 57 of the activation surface 38 are arranged in pairs, themembers of each pair cooperating to define opposing angled walls of arespective channel 40. In the particular channel configurationillustrated in FIG. 15, each channel 40 also comprises a respectiveceiling portion 59 between the two spaced-apart angled surfaces 57. Eachchannel 40 further comprises a pair of opposed side walls 60, each ofwhich interconnects an edge of a respective angled surface portion 57and a respective side edge of the ceiling portion 59 (at an upper corner61 of the channel 40).

In the arrangement illustrated in FIG. 15, the ceiling portion 59 ofeach channel 40 presents a substantially planar surface inspaced-relation to the heating surface 55. However, as will be explainedbelow in relation to FIG. 6, in other arrangements the ceiling portionmay alternatively present an arcuate surface towards the heating surface55.

As will be observed, the “saw-tooth” channel profile illustrated in FIG.5 can be considered somewhat similar to the profile illustrated in FIG.15, in the sense that it is also defined by an activation surface 38which is discontinuous in a manner effective to include angled surfaceportions arranged to form acute intersection angles with a planarheating surface. In the particular arrangement illustrated in FIG. 5, ofcourse, the heating surface is defined by the conduction element 36rather than the heater 24 itself.

It is believed that the aforementioned angled surfaces 57, and moreparticularly their acute intersection angles 58 to the heater surface 55aid, in the release of liquid aerosol precursor from the substratematerial of the fluid-transfer article 34. It is believed that the sharpcorners defined at the angled points of intersection between the angledsurfaces 57 and the heater surface 55 create improved vaporisation sitesfor the release of aerosol precursor, and allow the liquid to formmenisci along the corner edges of the channels 40, at the sites of theacute angles 58, on the heating surface 55. This has been found topromote more efficient and quicker heating and vaporisation of theprecursor liquid at the heating surface 55.

As will be observed, in the arrangement illustrated in FIG. 15, theheating elements 56 are arranged in relation to the channels 40 suchthat the pair of heating elements within each channel are offset fromthe centreline of the channel, to opposite sides. The heating elementsare thus adjacent and proximate to the resulting corner edges of thechannels 40 whilst nevertheless being spaced therefrom by a smalldistance. This allows the menisci of precursor liquid to form in thesharp corners of the channels immediately adjacent the heating elements56 for improved heating and vaporisation.

The acute intersection angles 58 may all be substantially equal to oneanother, but this is not essential and indeed some embodiments areenvisaged in which the acute intersection angles of the activationsurface may be different to one another. Each intersection angle may beof any magnitude between 0 degrees and 90 degrees—i.e. greater than 0degrees, and less than 90 degrees. Each intersection angle may be:greater than 10 degrees; greater than 20 degrees; greater than 30degrees; greater than 40 degrees; greater than 50 degrees; greater than60 degrees; greater than 70 degrees; greater than 80 degrees; less than80 degrees; less than 70 degrees; less than 60 degrees; less than 50degrees; less than 40 degrees; less than 30 degrees; less than 20degrees; less than 10 degrees; and any combinations of the foregoing.The optimum intersection angle 58 for any given arrangement may dependon a number of factors such as, for example, the viscosity of theaerosol precursor liquid; the porosity of the substrate material of thefluid-transfer article 34; the particular material of the substrate;and/or the temperature achieved by the heater 24 at the heating surface55.

Turning now to consider FIG. 16, there is illustrated a fluid-transferarticle 34 having another configuration of activation surface 38. Thefluid-transfer article 34 is illustrated as viewed from below theactivation surface 38, and in the absence of a heater 24 or a conductionelement 36 for the sake of clarity. Nevertheless, the notionaloperational position of the plane of the heating surface 55 which willbe defined by the presence of the heater 24 or a conduction element 36is illustrated in dashed lines for reference.

As will be observed from FIG. 16, the activation surface 38 is againdiscontinuous in a manner such that it includes a plurality ofspaced-apart angled surface portions 57, each of which will form anacute intersection angle with the heating surface 55 when engagedthereagainst. In the particular arrangement illustrated, theintersection angles are considerably smaller than in the configurationillustrated in FIG. 15 and may, for example, be less than 20 degrees,although this is not essential.

Furthermore, it will also be observed that the angled surface portions57 of the activation surface 38 are again arranged in pairs, the membersof each pair cooperating to define opposing angled walls of a respectivechannel 40. In the particular channel configuration illustrated in FIG.16, each channel 40 also comprises a respective pair of generally planarside walls 60 which are oriented so as to be substantially perpendicularto the plane of the heating surface 55 when the fluid-transfer article34 and a heater 24 (or conduction element 36) are interengaged. The sidewalls 60 extend upwardly from the edges of respective angled surfaceportions 57, and are interconnected by a ceiling portion 59 of therespective channel 40. In this arrangement, the ceiling portion 59 ofeach channel 40 defines an arcuate surface portion, which it will beunderstood forms part of the discontinuous activation surface 38 of thefluid-transfer article. The arcuate surface portion of each channel 40is arranged to oppose the heating surface 55, in spaced-relationthereto, and is concave towards the heating surface 55.

In preferred arrangements of the type illustrated in FIG. 16, it isproposed that the arcuate ceiling portion 59 of each channel will blendsmoothly into the side walls 60 of the channel, thereby eliminatingsharp corner edges in the upper region of the channel 40, distal to theheating surface 55. Such sharp corners can be seen, by comparison, inthe arrangement of FIG. 15, and are denoted at 61. It has been foundthat by eliminating such sharp corners from the upper regions of thechannels' cross-sectional profile, more efficient release or liberationof the aerosol precursor liquid from the porous substrate of thefluid-transfer article 34 may be achieved. This is because it has beenfound that liquid held in the wicking material has a tendency to collectat sharp corners of the channel profiles. Whilst this can be anadvantage at the points where the activation surface 38 contacts theheating surface 55 (and may thus be promoted by the provision of theabove-mentioned angled surface portions 57 and the resulting acuteintersection angles 58), it can present a disadvantage at the top ofeach channel 40. This is because if excessive precursor liquid collectsaround the upper regions of the channel 40, it can be drawn out of theporous wicking material and carried away from the heating surface 55 bythe airflow through the channel without having been heated and thusvaporised by contact with the heating surface.

In some arrangements, the or each channel 40 may be configured to havethe above-described arrangement of spaced-apart side walls 60 andinterconnecting arcuate ceiling portion 59 without the provision of theabove-described angled surface portions 57, such that the lower edges ofthe side walls 60 will be configured for direct contact with the heatingsurface 55 of a heater 24 or conduction element 36.

FIG. 17 illustrates an arrangement which is similar in many respects tothat illustrated in FIG. 15, but which incorporates an additionalfeature. As will be observed, whilst the arrangement illustrated in FIG.15 is configured to include two elongate heating elements 56 within eachair flow channel 40 of the fluid-transfer article 34, with each beinglocated adjacent and proximate to the corner edges of the channel 40, inthe arrangement of FIG. 17 there is only a single heating element 56within each channel 40. As will also be noted, in the arrangement ofFIG. 17, each heating element 56 is substantially aligned with thecentral longitudinal axis (centreline) of the respective channel 40.Noting that the heating elements 56 are thus spaced quite considerablyfrom the corner edges of the air flow channels 40, where the poroussubstrate material of the fluid-transfer article 34 contacts the heatersurface 55, it will therefore be appreciated that the heating elements56 are spaced quite considerably from the positions at which the aerosolprecursor liquid will most readily be drawn from the substrate material.In order to ensure that the precursor liquid is still properly heatedand vaporised, the heater 24 thus includes an additional fluid transportfeature to urge liquid across its heating surface 55 and towards theheating element 56, as will be described below.

The regions of the heating surface 55 adjacent each heating element areconfigured as fluid transport regions 62. There is thus a respectivefluid transport region 62 on each side of each heating element 56, eachfluid transport region 62 extending from a heating element 56 to (atleast) a respective lower corner edge of the channel 40.

In the particular arrangement illustrated in FIG. 17, each fluidtransport region 62 comprises a plurality of parallel capillary channels63 which each take the form of an open-topped groove formed in theheating surface 55 of the heater 24. As will be noted, the capillarychannels 63 each extend substantially perpendicular to the heatingelements 56, from the heating elements 56 to (at least) the lower corneredges of each channel 40, where the substrate material meets the heatingsurface 55. It is to be appreciated, however, that in some embodimentsthe entire heating surface 55 may be provided with an array of capillarychannels 63 which extend across its entire extent, and the heatingelements 56 may then be formed across the capillary channels 63 so as tointersect them. In such an arrangement, the capillary channels 63 willalso extend beneath the substrate material of the fluid-transfer article34, between neighbouring air flow channels 40.

The capillary channels 63 serve to urge a flow of precursor liquid fromthe substrate material of the fluid-transfer article 34, across theheating surface 55 and towards the heating elements 56, by capillaryaction.

The fluid transport regions 62 of the heating surface 55 may, either asan alternative to the capillary channels 63 or in combination therewith,incorporate one or more other fluid transport features. For example, insome embodiments it is envisaged that the fluid transport regions 62 maycomprise hydrophobic material to urge liquid across the regions. In somesuch arrangements, it is proposed that the hydrophobic material could beformed as a series of parallel elongate strips, in a similar pattern tothat in which the capillary channels 63 are proposed. The capillarychannels 63 themselves could be formed within a hydrophobic material.

In other embodiments, it is proposed to form the fluid transport regions62 from porous material. For example, it is possible to configure theheater 24 so that it comprises a liquid-impermeable substrate supportinga porous and liquid-permeable fluid transport layer on top, such thatthe transport layer would then define the heating surface 55 on whichthe heating elements 56 may be provided. The porous transport layer maybe formed from ceramic material.

In FIG. 18, there is illustrated an arrangement in which the heater 24has a laminate construction. More particularly, the heater 24illustrated in FIG. 18 comprises a supporting substrate 64 which may bestructural and which may be formed from a liquid-impermeable materialsuch as, for example, metal, a non-porous ceramic, or a suitable hardplastics material. The supporting substrate 64 supports an overlyinglayer 65 of porous material such as, for example, a porous ceramicmaterial. It is proposed that the porous material from which theoverlying layer 65 is formed may be liquid-permeable. The overlyinglayer 65 of the heater defines the heating surface 55 of the heater, andthe heating elements 56, which may again comprise resistive heatingfilaments, are laid directly on top of the porous layer, so as to be incontact therewith. The porous material of overlying layer 65 thusextends beneath the heating elements 56.

The porous layer may have a thickness of less than 5 mm. In otherembodiments it may have a thickness of: less than 3.5 mm, less than 3mm, less than 2.5 mm, less than 2 mm, less than 1.9 mm, less than 1.8mm, less than 1.7 mm, less than 1.6 mm, less than 1.5 mm, less than 1.4mm, less than 1.3 mm, less than 1.2 mm, less than 1.1 mm, less than 1mm, less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less than 0.6mm, less than 0.5 mm, less than 0.4 mm, less than 0.3 mm, less than 0.2mm, or less than 0.1 mm.

As will be observed, when the fluid-transfer article 34 is engaged withthe heater 24, the regions of the activation surface 38 which arelocated between the channels 40 make direct contact with the porousmaterial of the overlying layer 65 of the heater. Furthermore, it willbe noted that the heating elements 56 are located between the activationsurface 38 (within the channels 40 thereof) and the porous material ofthe overlying layer 65. The overlying layer 65 thus serves to absorbaerosol precursor liquid from the second region 34 b of thefluid-transfer article 34, via direct contact therewith, and thereafterto transfer the liquid towards the heating elements 56. As will beappreciated, because the heating elements 56 are formed directly on tothe porous material, liquid within the porous material will be broughtinto contact with both the sides of the heating elements 56, at theheating surface 55, and also with the underside of the heating elements56. The heating elements 56 are thus arranged for contact with a largervolume of precursor liquid, which has been found to improve theefficiency with which the liquid may be vaporised.

It is proposed that in some arrangements, the porous material of theheater 24 may be a porous wicking material, such as, for example, thematerials identified above as candidates for the substrate forming thefluid-transfer article 34.

There has been described in the foregoing one or more proposals for anaerosol delivery system, and parts thereof, that avoids or at leastameliorates problems of the prior art.

In one or more optional arrangements, a fluid-transfer article 34containing nicotine and/or nicotine compounds may be substituted orsupplemented with a fluid-transfer article configured to provide aflavoured vapour and/or aerosol upon heating of the fluid-transferarticle by the heater 24 of the apparatus 12. A precursor material forforming the flavoured vapour and/or aerosol upon heating is held withinpores, spaces, channels and/or conduits within the fluid-transferarticle. The precursor material may be extracted from a tobacco plantstarting material using a supercritical fluid extraction process.Optionally, the precursor material is nicotine-free and comprisestobacco-flavours extracted from the tobacco plant starting material.Further optionally, the extracted nicotine-free precursor material (e.g.flavours only) could have nicotine added thereto prior to loading of theprecursor material into the substrate of the carrier unit. Furtheroptionally, flavours and physiologically active material may beextracted from plants other than tobacco plants.

The features disclosed in the foregoing description, or in the followingclaims, or in the accompanying drawings, expressed in their specificforms or in terms of a means for performing the disclosed function, or amethod or process for obtaining the disclosed results, as appropriate,may, separately, or in any combination of such features, be utilised forrealising the invention in diverse forms thereof.

While the invention has been described in conjunction with the exemplaryembodiments described above, many equivalent modifications andvariations will be apparent to those skilled in the art when given thisdisclosure. Accordingly, the exemplary embodiments of the invention setforth above are considered to be illustrative and not limiting. Variouschanges to the described embodiments may be made without departing fromthe spirit and scope of the invention.

For the avoidance of any doubt, any theoretical explanations providedherein are provided for the purposes of improving the understanding of areader. The inventors do not wish to be bound by any of thesetheoretical explanations.

Any section headings used herein are for organizational purposes onlyand are not to be construed as limiting the subject matter described.

Throughout this specification, including the claims which follow, unlessthe context requires otherwise, the word “comprise” and “include”, andvariations such as “comprises”, “comprising”, and “including” will beunderstood to imply the inclusion of a stated integer or step or groupof integers or steps but not the exclusion of any other integer or stepor group of integers or steps.

It must be noted that, as used in the specification and the appendedclaims, the singular forms “a,” “an,” and “the” include plural referentsunless the context clearly dictates otherwise. Ranges may be expressedherein as from “about” one particular value, and/or to “about” anotherparticular value. When such a range is expressed, another embodimentincludes from the one particular value and/or to the other particularvalue. Similarly, when values are expressed as approximations, by theuse of the antecedent “about,” it will be understood that the particularvalue forms another embodiment. The term “about” in relation to anumerical value is optional and means for example +/−10%.

SEQUENCE LISTING

Not applicable.

The invention claimed is:
 1. A fluid-transfer article comprising: afirst region for holding an aerosol precursor and for transferring saidaerosol precursor to an activation surface of a second region of saidarticle, said activation surface being disposed at an end of saidarticle configured for thermal interaction with a heater of anaerosol-generation apparatus; wherein at least said second region isformed from a polymeric wicking material, wherein said polymeric wickingmaterial is porous, and is configured such that pore diameter in saidfirst region is greater than pore diameter in said second region.
 2. Thefluid-transfer article according to claim 1, wherein said first andsecond regions are both formed from said polymeric wicking material. 3.The fluid-transfer article according to claim 2, wherein said polymericwicking material is of greater hydrophilicity in said second region thansaid first region.
 4. The fluid-transfer article according to claim 1,wherein said polymeric wicking material comprises at least one substanceselected from the group consisting of: Polyetherimide (PEI); Polyetherether ketone (PEEK); Polytetrafluoroethylene (PTFE); Polyimide (PI);Polyethersulphone (PES); Ultra-High Molecular Weight Polyethylene(UHMWPE); Polypropylene (PP); and Polyethylene Terephthalate (PET). 5.The fluid-transfer article according to claim 1, wherein said polymericwicking material is a hydrophilic material that is configured totransfer fluid from said first region to said second region.
 6. Thefluid-transfer article according to claim 1, wherein said polymericwicking material comprises a graduated wicking action.
 7. Thefluid-transfer article according to claim 1, wherein said second regioncomprises at least one discontinuity in said activation surface to forma corresponding at least one channel between said activation surface andan opposing surface through which heat is conveyable to said activationsurface from the heater, said at least one channel configured forproviding a fluid pathway across said activation surface, said fluidpathway across said activation surface forming a portion of a fluidpathway between said first region and said second region.
 8. A carrierfor an aerosol precursor, the carrier comprising: the fluid-transferarticle according to claim 1; and a housing for engagement with theaerosol-generation apparatus, said housing being configured to provide afluid pathway between a first end that is disposed in fluid engagementwith an inlet of said aerosol-generation apparatus and a second end thatis disposed in fluid engagement with an outlet of saidaerosol-generation apparatus; the fluid-transfer article being providedwithin said housing.
 9. An aerosol-delivery system comprising: thecarrier according to claim 8 and the aerosol-generation apparatus havingthe heater.
 10. The fluid-transfer article of claim 1, furthercomprising: a liquid-impermeable peripheral wall surrounding at least aportion of said first region; wherein said first region comprises astorage substrate in which said aerosol precursor is held; and whereinsaid peripheral wall and said storage substrate are formed integrallyfrom the same material as a one-piece unit.
 11. The fluid-transferarticle according to claim 10, wherein said storage substrate is porous,and said peripheral wall is non-porous.
 12. The fluid-transfer articleaccording to claim 10, wherein said peripheral wall is defined by a skinformed from the material of said storage substrate.
 13. Thefluid-transfer article according to claim 10, wherein said peripheralwall substantially completely circumscribes said storage substrate. 14.The fluid-transfer article according to claim 10, wherein at least saidstorage substrate is formed from porous material, an outermost surfaceof which has been treated to render the outermost surface liquidimpermeable and thereby define said peripheral wall.
 15. Thefluid-transfer article according to claim 14, wherein said outermostsurface has been treated by a process selected from the group consistingof comprising: heat-treatment, and chemical treatment.
 16. Thefluid-transfer article according to claim 10, the fluid-transfer articlebeing provided in the form of a unitary monolithic element formed ofsaid material, wherein said peripheral wall defines an outer surface ofthe fluid-transfer article across substantially the entire extent ofsaid monolithic element, except said activation surface.
 17. Thefluid-transfer article according to claim 10, wherein said material is asecond polymeric wicking material, wherein said second polymeric wickingmaterial can be the same as said polymeric wicking material.
 18. Thefluid-transfer article according to claim 17, wherein said first andsecond regions are both formed from said polymeric wicking material. 19.The fluid-transfer article according to claim 10, wherein said materialcomprises a substance selected from the group consisting of:Polyetherimide (PEI); Polyether ether ketone (PEEK);Polytetrafluoroethylene (PTFE); Polyimide (PI); Polyethersulphone (PES);Ultra-High Molecular Weight Polyethylene (UHMWPE); Polypropylene (PP);and Polyethylene Terephthalate (PET).
 20. The fluid-transfer articleaccording to claim 10, wherein said material comprises Polyether etherketone (PEEK).
 21. The fluid-transfer article according to claim 10,wherein said material comprises Polytetrafluoroethylene (PTFE).
 22. Thefluid-transfer article according to claim 10, wherein said materialcomprises Polyimide (PI).
 23. The fluid-transfer article according toclaim 10, wherein said material comprises Polyethersulphone (PES). 24.The fluid-transfer article according to claim 10, wherein said materialcomprises Ultra-High Molecular Weight Polyethylene (UHMWPE).
 25. Thefluid-transfer article according to claim 10, wherein said materialcomprises Polypropylene (PP).
 26. The fluid-transfer article accordingto claim 10, wherein said material comprises Polyethylene Terephthalate(PET).
 27. The fluid-transfer article according to claim 10, whereinsaid second region comprises at least one discontinuity in saidactivation surface to form a corresponding at least one channel betweensaid activation surface and an opposing surface through which heat isconveyable to said activation surface from the heater, said at least onechannel configured for providing a fluid pathway across said activationsurface, said fluid pathway across said activation surface forming aportion of a fluid pathway between said first region and said secondregion.
 28. A carrier for an aerosol precursor, the carrier comprising afluid-transfer article according to claim
 10. 29. The carrier accordingto claim 28, the carrier being provided in the form of a consumable foran aerosol-delivery system, wherein said storage substrate contains aliquid aerosol precursor.
 30. An aerosol-delivery system comprising: thecarrier according to claim 28; and the aerosol-generation apparatushaving the heater.